FRONT BRAKE
4-38
WARNING
EWA39P1401
• Never try to pry out the brake caliper pis-
tons.
• Do not loosen the bolts “4”.
c. Remove the brake caliper piston dust seals
and brake caliper piston seals.
d. Repeat the previous steps to force out the
right side pistons from the brake caliper.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22391
CHECKING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.
1. Check:
• Brake caliper pistons “1”
Rust/scratches/wear
→
Replace the
brake caliper pistons.
• Brake caliper cylinders “2”
Scratches/wear
→
Replace the brake cal-
iper assembly.
• Brake caliper body “3”
Cracks/damage
→
Replace the brake
caliper assembly.
• Brake fluid delivery passages
(brake caliper body)
Obstruction
→
Blow out with compressed
air.
WARNING
EWA13611
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seals
and brake caliper piston seals.
EAS22411
ASSEMBLING THE FRONT BRAKE CALI-
PERS
WARNING
EWA13621
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake
components as they will cause the brake
caliper piston dust seals and brake cali-
per piston seals to swell and distort.
• Whenever a brake caliper is disassem-
bled, replace the brake caliper piston dust
seals and brake caliper piston seals.
EAS22440
INSTALLING THE FRONT BRAKE CALI-
PERS
The following procedure applies to both of the
brake calipers.
1. Install:
• Front brake caliper “1”
(temporarily)
• Brake hose gaskets
• Brake hose “2”
• Brake hose union bolt “3”
Recommended brake component replace-
ment schedule
Brake pads
If necessary
Piston seals
Every two years
Piston dust seals
Every two years
Brake hoses
Every four years
Brake fluid
Every two years and
whenever the brake is
disassembled
Recommended fluid
DOT 4
Brake hose union bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
New
Summary of Contents for Fazer FZ8-SA
Page 1: ...SERVICE MANUAL FZ8NA FZ8SA 2011 1BD 28197 E0 ...
Page 6: ......
Page 8: ......
Page 33: ...FEATURES 1 24 ...
Page 48: ...SPECIAL TOOLS 1 39 ...
Page 67: ...TIGHTENING TORQUES 2 18 ...
Page 75: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 26 ...
Page 78: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 EAS20410 LUBRICATION DIAGRAMS ...
Page 80: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 2 3 4 5 6 7 8 1 ...
Page 82: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 ...
Page 84: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 ...
Page 85: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Main axle 2 Oil pipe 3 Drive axle ...
Page 86: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 ...
Page 88: ...COOLING SYSTEM DIAGRAMS 2 39 EAS20420 COOLING SYSTEM DIAGRAMS ...
Page 89: ...COOLING SYSTEM DIAGRAMS 2 40 1 Thermostat 2 Water pump 3 Radiator 4 Radiator fan 5 Oil cooler ...
Page 90: ...COOLING SYSTEM DIAGRAMS 2 41 ...
Page 91: ...COOLING SYSTEM DIAGRAMS 2 42 1 Radiator cap 2 Radiator 3 Oil cooler 4 Thermostat ...
Page 92: ...CABLE ROUTING 2 43 EAS20430 CABLE ROUTING Handlebar front view FZ8NA ...
Page 94: ...CABLE ROUTING 2 45 Handlebar front view FZ8SA ...
Page 96: ...CABLE ROUTING 2 47 Handlebar right side view ...
Page 98: ...CABLE ROUTING 2 49 Engine right side view ...
Page 100: ...CABLE ROUTING 2 51 Handlebar left side view ...
Page 102: ...CABLE ROUTING 2 53 Engine left side view ...
Page 104: ...CABLE ROUTING 2 55 Rear frame left side view ...
Page 106: ...CABLE ROUTING 2 57 Frame top view ...
Page 108: ...CABLE ROUTING 2 59 Frame top view ...
Page 110: ...CABLE ROUTING 2 61 Frame top view ...
Page 112: ...CABLE ROUTING 2 63 Fuel tank left and bottom view ...
Page 114: ...CABLE ROUTING 2 65 Front brake right side view ...
Page 116: ...CABLE ROUTING 2 67 Front brake left side ...
Page 118: ...CABLE ROUTING 2 69 Rear brake ...
Page 120: ...CABLE ROUTING 2 71 Hydraulic unit top view ...
Page 122: ...CABLE ROUTING 2 73 Hydraulic unit front view ...
Page 124: ...CABLE ROUTING 2 75 Hydraulic unit left side view ...
Page 126: ...CABLE ROUTING 2 77 ...
Page 129: ......
Page 164: ...PERIODIC MAINTENANCE 3 35 ...
Page 262: ...CHAIN DRIVE 4 95 ...
Page 358: ...TRANSMISSION 5 93 ...
Page 387: ...THROTTLE BODIES 7 14 ...
Page 388: ...AIR INDUCTION SYSTEM 7 15 EAS27040 AIR INDUCTION SYSTEM ...
Page 395: ......
Page 396: ...IGNITION SYSTEM 8 1 EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM ...
Page 398: ...IGNITION SYSTEM 8 3 ...
Page 405: ...IGNITION SYSTEM 8 10 ...
Page 406: ...ELECTRIC STARTING SYSTEM 8 11 EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM ...
Page 408: ...ELECTRIC STARTING SYSTEM 8 13 ...
Page 414: ...CHARGING SYSTEM 8 19 EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM ...
Page 416: ...CHARGING SYSTEM 8 21 ...
Page 419: ...CHARGING SYSTEM 8 24 ...
Page 420: ...LIGHTING SYSTEM 8 25 EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM ...
Page 422: ...LIGHTING SYSTEM 8 27 ...
Page 426: ...SIGNALING SYSTEM 8 31 EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM ...
Page 428: ...SIGNALING SYSTEM 8 33 ...
Page 435: ...SIGNALING SYSTEM 8 40 ...
Page 436: ...COOLING SYSTEM 8 41 EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM ...
Page 438: ...COOLING SYSTEM 8 43 ...
Page 442: ...FUEL INJECTION SYSTEM 8 47 EAS27331 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM ...
Page 444: ...FUEL INJECTION SYSTEM 8 49 ...
Page 504: ...FUEL PUMP SYSTEM 8 109 EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM ...
Page 506: ...FUEL PUMP SYSTEM 8 111 ...
Page 510: ...IMMOBILIZER SYSTEM 8 115 EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM ...
Page 512: ...IMMOBILIZER SYSTEM 8 117 ...
Page 521: ...IMMOBILIZER SYSTEM 8 126 ...
Page 522: ...ABS ANTI LOCK BRAKE SYSTEM 8 127 EAS28790 ABS ANTI LOCK BRAKE SYSTEM EAS27730 CIRCUIT DIAGRAM ...
Page 524: ...ABS ANTI LOCK BRAKE SYSTEM 8 129 ...
Page 526: ...ABS ANTI LOCK BRAKE SYSTEM 8 131 EAS27740 ABS COMPONENTS CHART ...
Page 528: ...ABS ANTI LOCK BRAKE SYSTEM 8 133 EAS27750 ABS COUPLER LOCATION CHART ...
Page 532: ...ABS ANTI LOCK BRAKE SYSTEM 8 137 EAS27810 BASIC PROCESS FOR TROUBLESHOOTING ...
Page 570: ...ELECTRICAL COMPONENTS 8 175 EAS27973 ELECTRICAL COMPONENTS ...
Page 572: ...ELECTRICAL COMPONENTS 8 177 ...
Page 574: ...ELECTRICAL COMPONENTS 8 179 EAS27981 CHECKING THE SWITCHES ...
Page 576: ...ELECTRICAL COMPONENTS 8 181 ...
Page 598: ...ELECTRICAL COMPONENTS 8 203 ...
Page 606: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...